Manufacture of Food & Beverages (2nd Edn.)

***********Limited Edition- available in Photostat Version Only************

The Food and Beverages Industry is one of the leading industrial and business segments across the world, extending over a vast chain of production, distribution and retail lines. It is the mainstay of the much of the industrial and economic activities going around the world. The food industry is a complex, global collective of diverse businesses that supply much of the food and food energy consumed by the world population. Only subsistence farmers, those who survive on what they grow, can be considered outside of the scope of the modern food industry. The beverage industry refers to the industry that produces drinks. Beverage production can vary greatly depending on which beverage is being made. The food processing is one of the most under development almost exploited segment of agriculture industry. Food processing is the set of methods and techniques used to transform raw ingredients into food or to transform food into other forms for consumption by humans either in the home or by the food processing industry. Baking is the traditional technique of prolonged cooking of food by dry heat acting by convention. Bakery product, bread products, biscuit products, and other products are a major growth area. Food preservation is one of the major parts of food processing.
The Indian food industry was estimated at over $182 billion, accounting for about two-thirds of the country's total retail sector. Expected growth of food industry is to grow $300 billion by 2015 and by 2025, it is expected to be worth $344 billion. Consumption of non-alcoholic beverages is expected to increase by 16.5-19% over the next three years as more people are trading up to packaged drinks. Corporate manufacturers of non-alcoholic beverages are expected to grow at an annual rate of 16.5% and non-corporate manufacturers at 19%. The estimates are based on an assumed gross domestic product growth of 7%, which is much higher than the 5% growth.
The content of the book includes information about food and beverages. The major contents of this book are project profiles of projects like Food Industry, Beverage Industry, Beer, Biscuit, Bread, Chocolate Drinks (Liquid Form), Corn Flakes, Date Syrup, Date Paste, Date Jam & Date Drinks, Health Drink, Indian Made, Foreign Liquor, Lychee Juice, Packaged Drinking Water, Potato Powder, Flakes and Granules with Cold storage, Soft Drink (Aerated), Sugarcane Juice in Tetra Pack, Tomato Concentrate & Ketchup, Wine from Grape.
Project profile contains information like introduction, properties, B.I.S specification, uses and applications, manufacturing process, manufacturing process flow diagram, plant and economics, land and building, plant and machinery, fixed capital, working capital requirement/month, total working capital/month, cost of project, total capital investment, turn over/annum, profit sales ratio, rate of return, breakeven point (B.E.P).
This book is very useful for new entrepreneurs, technical institutions, existing units and technocrats.

Sample Chapters

Health
drinks are the drinks containing natural minerals vitamins like A and C
most of
which are plant based and having rich diet components .With people
turning more
health conscious the non carbonated beverage segment has become one of
the
fastest growing and most exciting businesses at the moment. The liquids
which
are healthy for consumption such as fruit juices dairy products milk
with honey
buttermilk fruit juices etc comes in this category.

A
Cocoa beverage is
manufacture by the mixing
ingredients of cocoa powder, milk powder, sugar and vitamins
homogeneously.
There is much more popularity of cocoa beverages as health drinks. It
can be
substitute of milk products. There is availability of technology for
manufacturing of the cocoa beverages. All the plant and machineries are
available indigenously in India.
There is scarily available of cocoa powder. The product has good market
demand.
The market demand of cocoa beverages increases about 10% per annum.
There is
necessity of special labelled packaging material required for packing
the cocoa
beverages granules. Granules should be packed in aseptic condition.
There
should not be any microbial load especially no pathogenous should be
there.
There is environmental pollution problem arises especially liquid and
gases
pollution. Environmental pollution can be overcome by proper treatment
of the
raw material. This is good project provided quality product is
manufactured with
economic price.

Cocoa
beverage powder mixes from which chocolate drinks may be made by
dispersing the
powder mix in milk usually contain from 2 to 25% cocoa, 0.5 to 2%
emulsifier,
up to 1% flavour all or most of the remainder being made up of sugar or
a
filler, such as malto-dextrin, or a mixture of sugar and a filler. A
sugar-free
cocoa beverage powder mix from which a chocolate drink may be made
typically
contains cocoa and whey together with small amounts of an emulsifier,
such as
lecithin, and of an artificial sweetener and flavour. Generally, the
ingredients of the cocoa beverage powder mix are batch mixed and then
agglomerated to enhance the appearance and performance such as
miscibility and
flow ability. However, when such cocoa beverage powder mixes are
dispersed in
milk to prepare the beverage, the physical properties are sometimes
less then
desired.

Chocolate
flavoured dry powdered food products of the type intended to be
dispersed in
water and a process for their manufacture characterised by high
wettability and
dispersibility in water comprising continuously moistening a mixture of
a
chocolate flavoured powder and anhydrous milk powder while the material
is in
dispersed condition, causing the moistened particles of the material,
while
dispersed in a treatment zone, to contact and permanently adhere
together in
the form of light moist random aggregates of random shape and of a size
substantially greater than the size of the original particles, the
aggregates
leaving said zone in dispersed condition and having a total moisture
content of
from 8 to 20%, and then removing excess moisture from the aggregates
without
any substantial amount of crushing of the same, the final product being
a
free-flowing granular material. The excess moisture is removed from the
aggregates by permitting them to rest without handling for from 1 to 2
minutes,
for example on a moving belt until the structures become firm. After
the period
of rest, the material is less sticky, is relatively free flowing, and
the
aggregates have sufficient strength for handling and drying without
serious
breakup or crushing.

Properties

It
should be dissolved in the water and milk to form homogeneous solution.

1. It
should have good flavour and pleasant taste.

2. It
is easily digestible.

3. It
can be stored at room temperature for long time.

4. It
has owned characteristics colour and flavour.

Physical
Properties of Cocoa
Powder

There
are several physical properties of cocoa powder that are important to
both the
consumer and food manufacturers (1). The pH and color of cocoa powders
are
important characteristics and can vary significantly depending on the
source of
cocoa beans and how they are processed. Natural cocoa powders have
lower pH and
a characteristic light brown color while alkalized cocoa powders have
higher pH
and darker colors that range from dark brown to brownish red to dark
red to
black.

The
ability to produce cocoa powders that are either darker in color,
including
dark red or even black, have important uses in the food industry. The
dark
color of alkalized cocoa powder yields a rich dark brown color to
cakes,
cookies, and brownies that are desirable. The milder flavor of
alkalized cocoa
powder also provides a unique and desirable taste for certain products.
In
particular, alkalized cocoa has less sourness (acidity) and lower
bitterness
than untreated, natural cocoa powder. Another advantage of alkalized
cocoa
powder is its increased solubility in certain beverage applications.

pH:
The pH of cocoa powder is a measure of the degree of acidity or
alkalinity on a
14 point scale. A value of pH 7 is neutral, while values less than pH 7
are
acidic and values above pH 7 are alkaline. In a scientific study
published by
Miller et. al. in 2008(2), the pH of natural and alkalized powders was
measured. Light brown natural powders ranged from pH 5.4-5.8. Lightly
alkalized, darker brown cocoa powders had values ranging from pH
6.8-7.2.
Moderately alkalized dark brown and brownish-red powders had pH values
in the
range of 7.2-7.5 and heavily alkalized dark red and black powders had
pH values
ranging from 7.6-8.1. All of these pH values for cocoa powders are
within safe
and acceptable ranges for food products and for cocoa powders in
particular.

Colour:
One way to objectively measure the degree of lightness or darkness of
cocoa
powder is by using the Hunter “L” scale value where a high value
represents
lighter colours and a lower value represents darker colours. In a study
the
Hunter “L” values for natural cocoa powders ranged from 38-41
exhibiting light
brown colours. In contrast, alkalized cocoa powders had “L” values
ranging from
16-35 depending on the degree of alkalization. The colours for these
alkalized
cocoa powders ranged from medium brown and brownish red at the higher
end of
the ‘L” scale to dark red and black at the low end of the scale.

Nutrition:
Cocoa powder is
nothing more than a cocoa bean
seed with most of the fat removed. It, therefore, contains a wide
variety of
plant nutrients necessary for the seed to grow.

Uses

Aside
from delivering essential vitamins and minerals and increasing energy,
the
following are other benefits of health drinks:

1. Satisfies
the hunger and gives a sense of fullness. In a fast-paced, busy
environment
people are living in today, it is a must to have a source of energy at
all
times. One of the reasons why more and more people are into health
drinks is to
make up for the lost vitamins and minerals when they need to skip meal
due to
busy schedule.

2. Improves
overall health. Since most health drinks are packed with vitamins and
minerals,
it can help you fight off common diseases by consuming it regularly.

3. Helps
enhance mental stability. The nutrients in most health drinks are aimed
to
produce oxygen that keeps the blood vessels clear. Once a person takes
in these
nutrients regularly, it can help them have greater focus in the things
that
they do either at work or at home.

MANUFACTURING
PROCESS

Basic
Raw Material
Required

1. Cocoa
Powder

2. Sugar

3. Milk
Powder

4. Permitted
Food Preservative.

5. Minerals
and Vitamins

Plant
& Machinery
Required

1. Digital
Weighing Machine

2. Jacketed
Close Mixing Machine Containing Ribbon Conveyor Blade

3. Extruding
Machine

4. Continuous
Cross Flow Funnel Dryer or Roller Dryer

5. Aseptic
Automatic Vacuum Filling, Weighing and Sealing Machine

Most
Probable Formula

Fat
Content Cocoa
Powder
20%-25%

Sugar
Powder
40%-45%

Milk
Powder
35%-40%

Minerals
and Vitamins
2%-5%

Process

Take
above all the ingredients by weight and put in the jacketed mixing
machine made
by SS 304 containing ribbon blade inside the mixer. All the powder
products are
mix homogeneously. Homogeneous mixed products mixed with measured
quantity
water (Content 40% on the dry basis wt of the powder) and mixed
properly, mixed
dough is pass through the extruder, extruder content dies of diameter 2
mm. to
4 mm. Extruded product collects in the pot and dried through the funnel
drier
of temperature maintained 75°C-80°C and inlet air content humidity less
than
15% Dry the ingredients and product aseptically by using vacuum packing
machine. Check quality of vacuum pack products and store at room
temperature
for marketing.

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